Visible ceiling suspension system



March 28, 1967 G. A. HOFFMANN, JR 3,310,922

VISIBLE CEILING SUSPENSION SYSTEM Filed April 15, 1964 5 Sheets-Sheet 1I it 2 g 2 A TTURNEVE.

G. A. HOFFMANN, JR 3,310,922

VISIBLE CEILING SUSPENSION SYSTEM 5 Sheets-Sheet 2 5:: FM 15W 5::

March 28, 1967 Filed April 15, 1964 March 28, 1967 G. A. HOFFMANN, JR3,310,922

VISIBLE CEILING SUSPENSION SYSTEM Filed April 15, 1964 4 TTORNEYS.

United States Patent C 3,310,922 VISIBLE CEILING SUSPENSION SYSTEMGeorge A. Hotfrnann, .Jn, Kansas City, Mo., assignor, by

This invention relates to the suspension of acoustical insulation panelsand suspending means for acoustical insulation panels and refers moreparticularly to such means and suspension systems wherein a visiblearray of acoustical panel support means is provided, the said visiblearray so formed and covered or painted as to simulate a wood or otherlike material support system.

There have been previously provided a very great number of acousticalinsulation panel suspension systems. Conventionally, however, it isattempted and has been desirable to hide the suspension means for suchpanels to as great a degree as possible. This has been preferred forappearance reasons and also to maximize the panel area presented to theinterior of a ceiling. Some suspension systems, it is true, do displayrunners or supports to a greater or lesser degree which carry theacoustical panels. However, these are often painted to resemble thepanels or otherwise semi-obscured or merely deplored as neccessitiesrather than sought as a goal.

The basic purposes of the instant invention include the development of amethod for suspending multiple frame-type supports at predeterminedintervals from existing structural members while simultaneouslyproviding a framework adapted to support ceiling panels placed aboveeach section of module formed by the support members. The supportmembers, per so, are designed to simulate exposed beam-type framingmembers when ceiling panels are set in place above each section ormodule formed by the framing supports. The beam-type framing supportsare designed to be suspended below existing structural members by use ofsuitable attachment clips and suitable hanger or furring straps toprovide sufficient space between the structural members and framingsupports to conceal mechanical equipment. Furthermore, the main beamsupports are designed for parallel installation or can be interlockedwith cross beam supports at right angles to form a network of framingmembers connected in square or rectangular modules to support theceiling panels placed above each square or rectangular section ormodule. The ceiling panels are held in place in the modules by cornerclips designed to restrict the movement of ceiling panels in anyhorizontal direction, but to permit upward movement so the panels may beremoved for access to mechanical equipment installed in the area betweenthe structural members and the beam-type ceiling support members.

An object of the invention is to provide a suspension system forinsulation panels of either thermal or acoustical character whereineither rigid, nonresilient and noncompressible panel boards ordeformable semi-rigid tiles may be employed therewith.

Another object of the invention is to provide a suspension system foracoustical and thermal insulation tiles, which suspension system isadapted to itself form an attractive decorative feature, whileadditionally performing all the desired functions of a drop ceilingsuspension system and also adequately though flexibly supporting saidvarious types of tiles.

Another object of the invention is to provide a drop ceiling suspensionsystem wherein the suspension system itself comprises a decorativefeature and wherein same appears to be of solid massive constructionadapted to simulate a wood beam system or the like, yet wherein3,31%,922 Patented Mar. 28, I967 ice the suspension system itself isvery light, easy to handle, assemble and remove for repair orreplacement or accessibility therebehind.

Another object of the invention is to provide a drop ceiling suspensionsystem wherein the suspension system itself forms an importantdecorative element of the ceiling and is fully accessible to view yetwherein a maximum surface of the acoustical or thermal tiles themselvesis exposed for the various purposes thereof.

Other and further objects of the invention will appear in the course ofthe following description thereof.

In the drawings, which form a part of the instant specification and areto be read in conjunction therewith, embodiments of the invention areshown and, in the various views, like numerals are employed to indicatelike parts.

FIG. 1 is a perspective view from below of a drop ceiling suspensionsystem utilizing acoustical or thermal insulation tiles therewithembodying the instant invention.

FIG. 2 is a perspective View from above of a preferred suspensionconstruction of the type seen in FIG. 1, parts thereof cut away tocondense the view in the space available and also to better show theconstruction of the individual elements.

FIG. 3 is a view taken along the line 33 of FIG. 2 in the direction ofthe arrows.

FIG. 4 is a view taken along the line 4-4 of FIG. 2 in the direction ofthe arrows.

FIG. 5 is a plan view from above of the upper lefthand corner of FIG. 2,that is, a fragmentary portionof the figure of FIG. 2, with anacoustical panel emplaced.

FIG. 6 is a view taken along the line 6-6 of FIG. 5 in the direction ofthe arrows.

FIG. 7 is an exploded detail perspective of the corner clip as seen inthe various views of FIGS. 2-6, inclusive.

FIG. 8 is a view analogous to that of FIG. 2, but showing a modifiedform of suspension structure and suspending clip means therewith.

FIG. 9 is a perspective view from above of a suspension systemconstruction analogous to those seen in FIGS. 2 and 8 but showing amodified engagement of certain parts whereby to facilitate end and sidewall system closure, parts thereof cut away to condense the View in thespace available and also to better show the construction of theindividual elements.

FIG. 10 is a view taken along the line liP-10 of FIG. 9 in the directionof the arrows.

Conventional acoustical insulation panel boards or tiles may be rigid,nonresilient and noncompressible pieces or deformable yet semi-rigid.Such may be the case in either instance when a fibrous mot, such as aglass fiber mat bonded with a plastic resin is employed. In such case,where the glass fibers are stiff and heavy and the glass fiber-resinmixture is relatively high density, a brittle punky structure may beemployed.

On the other hand, a resilient, deformable yet essentially semi-rigidacoustical insulating panel may be provided. Functionally, thisdescription means that the tile is deformable relative to itself todecrease its dimension in any direction and yet of sufiicient rigidityand resilience to snap back to its original shape after the deformingforce is removed and, when returned to that shape, retain it even whenbeing suspended only by the edges thereof. A typical resilient fibrousmat fabricated to these specifications may be preferably formed of glassfibers having an average diameter of less than 10 microns and preferablyabout 4 microns randomly oriented in the mat. Glass fibers of thisdescribed character may be bonded together with a plastic, preferablythermosetting resin to form this mat. A number of plastics are suitablefor such a binder, including phenol condensation products,

melamine resins, urea-formaldehyde resins, urea-melamine resins andvinyl chloride acetate resins. Such a binder is preferably employed inthe ratio of 15-35 percent by weight of the thermal insulation or 17-55percent by weight based on the weight of the glass fibers. The fibersand binder, when bonded together to compose the mat should typicallyform a mat having a density in the range of 2-5 pounds per cubic foot.The above description is illustrative and not limiting with respect totypical optimal tiles to be employed with the instant invention.

Since drop ceiling installations are rapidy superseding theold type ofacoustical tile adhered to a finished ceiling, it is important to notethat fire code regulations require all tile used in drop ceilings to beof a fireproof nature. Tile that would burn does so much more readilyand violently if there is an air space behind it. The tile disclosed isfireproof and meets the fire code requirements in addition to possessingthe qualities set forth.

In both modifications of the inventive panel suspension system to bedescribed, the panel tiles may be removed from and replaced into thesuspension means at will. This feature permits access to the space abovethe tiles wherein heating, ventilating and air conditioning ducts,electrical conduits for lighting or other purposes are normallydisposed; thus making such equipment accessible. It further permits theremoval of the tile from the suspension means for cleaning orresurfacing and restoration to place in the suspension system Withoutany disturbance of the elements of the latter.

Referring first to FIGS. 2-7, inclusive, wherein is shown the preferredconstruction of the insulation paneling system, at 10 and 11 aregenerally designated two main beams, each engaged by a pair of crossbeams generally designated 12 and 13, beam 10 also shown engaged by afragmental portion of another cross beam generally designated 14. Eachbeam member has a floor a, side walls 12 and (vertical with respect tothe horizontal floor) and horizontal upper flanges d and 2. Thus, as anexample, cross beam 13 has floor 13a, vertical walls 13b and 130 andhorizontal upper flanges 13d and 132. Likewise, main beam 11 has floor11a, side walls 11b and 11c and overlying horizontal flanges 11d and11e. Such will not be repeated for each of the other members, but theyare like lettered for the given number of the beams. Punchout lock tabs11 (particularly see FIG. 3) and 101 are provided centrally of side wallzones 19g and 11g from which the upper flanges 11d and lie and 19d .andlite have been removed and wherein vertical slots 11/1 and ltlh havebeen provided. Slots 1012 and 11h extend approximately one-third theheight of the side walls.

The flange removal zones 11g, the slots 11k and the punch-out tabs 11 aswell as the analogous beam members are provided in the cross beam-mainbeam engagement zones for purposes to be described Referring to thecross beams 12, 13 and 14, at the ends thereof, and inwardly thereofsubstantially a distance equal to half the width of the floors 13a oritla are slots 121', 113i and 14: which extend entirely across thefloors 12a, 13a and 14a and two-thirds, approximately, of the height ofthe walls 121) and 120, 135 and 130 and 14b 14c. Thus, slots 12f, 131'and 141' mate with slots 1% and 1111 to provide an engagement of thecross and main channel members whereby the floors 12a, 13a and 14a lieon the floors 11a and 10a in face-to-face relationship.

The suspension clips cooperate between the main beams, their upperflanges lle and 11d and We and 10d and any overlying structural. Theycomprise base pieces generally designated 15 having a top platform 15awith an opening 15b therethrough, downwardly extending lateral extendingflanges 15c and downwardly extending end flanges 15a. A conventionalexternally threaded bolt 16 passes its lower end through opening 15b andengages nut 16a therebelow. The head 16b of the bolt overlies the lowerL-leg 17a connected to upper L-leg 17b of support generally designated17 having a series of perforations 170 in the upper end thereof topermit various height attachment to an overlying structural ceilingmember or the like. It should be understood that such suspension memberis merely preferred and not necessary as will be evidenced by thedescription of another support member with respect to FIG. 8.

The corner clip which is adapted to receive one edge corner of anacoustical panel of the type described is best seen in FIG. 7 andcomprises a lower member generally designated 18 having a central slot18a and a lower edge 18b on which it is adapted to rest on a cross beamor cross beams lower surfaces 13a and 14a, for example. Additionally,there are provided side edge slots 18c which define arms 18d which maybe bent to one side as seen in the various views, particularly FIG. 5,to overlie and abut against the outer faces of the side walls, forexample 14b and 13c of cross beams. An upper engaging piece generallydesignated 19 has a lower edge 19a, a central slot 1% adapted to engageslot 18a of member 13 and side slots 19c defining side partial arms 190.which are analogous to arms 180?, but are generally not bent to one sideas they will overlie and abut against the outside surfaces of side wallsof main beams such as 10b and 10c.

In operation, a grid or array of longitudinal and cross beams are madeup by engaging the end slots 121?, for example, with the slots 11k and14th of main beams and punching out the engaging members 10] and 11f tosecure the engagement. The same is done with respect to a cross membersuch as 13. Corner members are then inserted as described at least intwo opposing (catercornered) engagements between cross and main beamsand suspension members are installed in each main beam preferablybetween cross beam engagements therewith. The suspension members may befirst nailed up and the grid array then attached thereto or vice versa,the former easier. As the members 15 can be rotated they may be easilyfitted into the flanges, for example 11d and 11s and then turned atright angles to make a posi tive engagement with the downwardlyextending flanges in frictional engagement with the side walls 11b andlie. The panel members are then laid on top of the structurals with thepanel being of such area as to abut up against the cross corner membersin opposed corners with the side edge there also abutting against thebolt shafts 16 for further positioning. Four corner members may be usedif desired to give a complete circumferential edge engagement or cornerengagement of the panels. If the panels are resilient they may besnapped in from below after the grid array has been applied in place,or, alternatively, if resilient or rigid, may be laid in to the formedarray before same is engaged with the ceiling suspension members 15.

To splice either longitudinal or cross beam members, a member as seen at20, generally designated, is provided which has a floor 20a, side walls20b and 20c and underlying top flanges 26d and 20a. The engagement ismade by crimping down the flanges 12d and 12a to engage and crimpdownwardly also the already V-punched center portion of the member 20 oneach flange 26d and 20e thereof.

The structural array of FIG. 8 differs from that seen in the foregoingfigures only in that (1) no corner members are employed, (2) differentsuspension members are employed, and for an additional purpose, and (3)a further panel receiving and positioning flange structure is provided.These will now be described.

All parts identical to parts in FIGS. 2-6, inclusive, will be numberedthe same, but primed, and not redescribed.

Instead of short horizontal flanges 12a and 132 on cross beams 12 and13, there are provided half beam width flanges 12 and 13 on the freeedges of which are erected vertical flanges 12k and 13k adapted toreceive and abut against the opposed edges of an insulation panelmember.

Abutment and positioning for the other panel edges erally designated 21having base portions 21a adapted to frictionally fit within the beamflanges, walls and floors. Connected to the side edges of base portions21a are crimped extensions 21b, which lie against, for example, walls101) and 100'. Slotted upper extensions 210 may be connected to overheadstructurals in various conventional ways.

Beam interconnections, interlockings and splicings are accomplished inthe same manner as previously described with respect to the earlierdescribed figures.

FIGS. 9 and 10 differ from the showings of FIGS. 2 and 8 only in thatthe engagement of cross beams with main beams at a side or end wall ismade more versatile. That is, the engagements between cross beams with amain beam, the latter lying along a side wall or an end wall is providedsuch that the main beam may be adjusted inwardly or outwardly on thecross beams whereby a snug, secure, aligned engagement is possiblewithout having a plurality of slots cut in the cross beams or withoutexcessive necessity of splicing and cutting of cross beams. Thus,referring specifically to the figures, if there are two main beams 40and 41, with main beam 41 lying parallel to and along a side or end wallof a room, the following structural relationships will be present orprovided. Cross beams 42 and 43 are adapted at the right-hand endsthereof in the view of FIG. 9 to engage main beam 40 in the identicalmanner of engagement of cross beams with main beams previouslydescribed. Thus, this is a rigid engagement without relative movementpossible in the same horizontal plane of main beam 40 and cross beams 42and 43. A corner clip generally designated 44 is attachable and usablein the same manner as previously described.

However, the engagement of the left-hand ends of cross beams 42 and 43with main beam 41 is not an engagement of the character previouslydescribed. Instead of slots interengageable between the cross beams andthe main beam as previously described, instead U- shaped openings 41aand 41b are cut the entire height of the flange whereby the trough crossbeams 42 and 43 may slide to and fro in the same plane in lie-inengagement with the main beam 41. This is most clearly seen in FIG. 10.Thus it is seen that only a very small portion of the cross beams 42 and43 need actually lie within the trough of main beam 41 for theengagement to be complete. A suspension member generally designated 45may in its upper portion abut against and engage the wall against whichmain beam 41 lies whereby to support main beam 41 therefrom.

From the foregoing it will be seen that this invention is one welladapted to attain all of the ends and objects hereinabove set forthtogether with other advantages which are obvious and which are inherentto the structure.

It will be understood that certain features and subcombinations are ofutility and may be employed without reference to other features andsubcombinations. This is contemplated by and is within the scope of theclaims.

As many possible embodiments may be made of the invention withoutdeparting from the scope thereof, it is to be understood that all matterherein set forth or shown in the accompanying drawings is to beinterpreted as illusstrative and not in a limiting sense.

6 Having thus described my invention, I claim: 1. A structural unit fora suspended ceiling system comprising a pair of parallel horizontal mainbeam members, said members each C-shaped in transverse section with 5 ahorizontal bottom wall and two vertical side walls connected thereto,

the upper edges of said side walls having inwardly oriented horizontaltop flanges connected thereto,

a pair of parallel horizontal cross beam members normal to the mainbeams and laterally spaced from one another,

said cross beams in transverse section like the main beams, includingbottom and side walls and top flanges,

a continuous slot in each cross beam adjacent each end thereof extendingacross the bottom wall and up a portion of the side Walls,

the main beam side wall top flanges relieved at desired cross beamengagement zones with the main beam side walls thereat also verticallyslotted downwardly from their top edges,

said cross beams each engaged with an adjacent side wall of each of saidmain beams by means of said slots to form a rectangular structural unit,

a rectangular ceiling tile received on the upper surfaces of adjacenthorizontal flanges of said main and cross beams whereby tile side edgesoverlie the beam bottom walls between side walls,

and means mounted on upwardly facing port-ions of said beams engagingside edges of said tile aiding in fixing its position on said unit.

2. A unit as in claim 1 wherein said fixing means comprise at least onecorner clip, same comprising a pair of flat, rectangular, oppositelyslotted self-engaging plates normal to one another, one said platehaving slots engaging the flange relieved main beam vertical sides andthe other having slot defined side edge tabs lying outside the verticalside walls of a cross beam, said clip positioned at a corner juncture ofcross and side beam and received within the side walls of each.

3. A unit as in claim 1 wherein the fixing means comprises a verticalflange fixed to the free edge of the nonadjacent cross beam tophorizontal flanges.

4. A unit as in claim 1 wherein one of the main beams in one of thevertical side walls adjacent the other main beam is completely relievedof the side wall height thereof at the desire-d cross beam engagementzones whereby adjustable maincros-s beam engagement is achievable.

References Cited by the Examiner UNITED STATES PATENTS FOREIGN PATENTS642,849 6/1962 Canada.

FRANK L. ABBOTT, Primary Examiner. RICHARD W. COOKE, JR., Examiner.

L. R. RADANOVIC, R. S. VERMUT,

Assistant Examiners.

1. A STRUCTURAL UNIT FOR A SUSPENDED CEILING SYSTEM COMPRISING A PAIR OFPARALLEL HORIZONTAL MAIN BEAM MEMBERS, SAID MEMBERS EACH C-SHAPED INTRANVERSE SECTION WITH A HORIZONTAL BOTTOM WALL AND TWO VERTICAL SIDEWALLS CONNECTED THERETO, THE UPPER EDGES OF SAID SIDE WALLS HAVINGINWARDLY ORIENTED HORIZONTAL TOP FLANGES CONNECTED THERETO, A PAIR OFPARALLEL HORIZONTAL CROSS BEAM MEMBERS NORMAL TO THE MAIN BEAMS ANDLATERALLY SPACED FROM ONE ANOTHER, SAID CROSS BEAMS IN TRANSVERSESECTION LIKE THE MAIN BEAMS, INCLUDING BOTTOM AND SIDE WALLS AND TOPFLANGES, A CONTINUOUS SLOT IN EACH CROSS BEAM ADJACENT EACH END THEREOFEXTENDING ACROSS THE BOTTOM WALL AND UP A PORTION OF THE SIDE WALLS, THEMAIN BEAM SIDE WALL TOP FLANGES RELIEVED AT DESIRED CROSS BEAMENGAGEMENT ZONES WITH THE MAIN BEAM SIDE WALLS THEREAT ALSO VERTICALLYSLOTTED DOWNWARDLY FROM THEIR TOP EDGES, SAID CROSS BEAMS EACH ENGAGEDWITH AN ADJACENT SIDE WALL OF EACH OF SAID MAIN BEAMS BY MEANS OF SAIDSLOTS TO FORM A RECTANGULAR STRUCTURAL UNIT, A RECTANGULAR CEILING TILERECEIVED ON THE UPPER SURFACES OF ADJACENT HORIZONTAL FLANGES OF SAIDMAIN AND CROSS BEAMS WHEREBY TILE SIDE EDGES OVERLIE THE BEAM BOTTOMWALLS BETWEEN SIDE WALLS, AND MEANS MOUNTED ON UPWARDLY FACING PORTIONSOF SAID BEAMS ENGAGING SIDE EDGES OF SAID TILE AIDING IN FIXING ITSPOSITION ON SAID UNIT.